Roof deck and parapet structure

ABSTRACT

A roof transition assembly for a roof deck having a corrugated sheet and a rigid sheet wherein a base component is positioned at the perimeter of the roof deck and has two legs. The first leg secures the base component to the corrugated sheet, and the second leg extends from the first leg, generally parallel to a free edge of the roof deck. The second leg includes an anchoring surface. An upper component positioned at the perimeter of the roof deck has a connector portion and an anchor portion. The anchor portion is secured to the roof deck, and the connector portion extends from the anchor portion and overlays and is secured to the anchoring surface of the base component, thus anchoring the base component and upper component to the roof deck.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of the filing date ofco-pending Utility Application Ser. No. 09/614,016, filed Jul. 11, 2000by C. Lynn Nunley entitled “ROOF DECK TERMINATION STRUCTURE,” which is adivisional application of Provisional Application Serial No. 60/043,522filed Apr. 15, 1997 by C. Lynn Nunley entitled “ROOF DECK TERMINATIONSTRUCTURE,” now abandoned, the disclosures of which are incorporatedherein by reference in their entirety for all purposes.

FIELD OF THE INVENTION

[0002] The present invention relates to improved roofing components.More particularly, this invention relates to transition assemblies forprotecting and reducing the stresses at roof deck perimeters and parapetwalls.

BACKGROUND OF THE INVENTION

[0003] Conventional roof deck design typically calls for wood blockingat the termination points of the roof deck assembly and at thetransitions between multiple roof decks, such as expansion joints. Thewood blocking is used to provide starting and stopping points for theroof decking, roof insulation, and the roof covering, as well as ananchorage medium for sheet metal flashing and gutter hardware. The woodmembers can be made a part of the assembly, or can act as fillers,independent from the roof deck assembly, being mounted to a wall orother non-roof deck component. Roof deck stress occurs at the jointsbetween the wood blocking and roof assembly and at the terminationpoints of the roof deck.

[0004] As relatively thin, plate-like structures, roofs experiencediaphragm forces due to building movement induced by wind and seismicloading. These diaphragm forces result in stress between roofcomponents, especially at roof transition and termination points. Thesestresses are transferred to the wood blocking and roof supportingstructure. Further stress is caused by linear expansion and contractionforces. Since the roof components are formed of different materials withdifferent coefficients of thermal expansion, they can undergosignificant relative thermal growth. Such relative movement results inlocal stresses between the roofing and blocking materials and betweenthe roof assembly and the roof support system. These stresses also occurat the junctures between multiple roof assemblies.

[0005] Further problems arise with wood blocking as the wood ages. As itdries, the wood shrinks, warps and buckles, losing its dimensionalstability and its ability to retain fasteners. This presents problemsfor building flashing as it causes substrate movement and fastenerloosening resulting in leaks and failures.

[0006] To deal with these problems, there is need for improvedprotection from the stresses between the roof deck and the roofsupporting structure at the roof deck perimeter and between adjoiningroof assemblies.

SUMMARY OF THE INVENTION

[0007] A roof transition assembly suitable for roof perimeter and walltransitions. The roof transition assembly is for use with roof deckswith a sheet of rigid material and a sheet of corrugated material. Theroof transition perimeter assembly comprises a base component and anupper component. The base component has two legs: one secured to thesheet of corrugated material, the second extending upward along the roofdeck edge. The base component further has a connecting surface forattachment to the upper component. The upper component has a connectorportion and an anchor portion, with the anchor portion secured to thetop of the roof deck. The connector portion extends from the anchorportion, overlays, and is secured to, the connecting surface of the basecomponent, thus anchoring the transition assembly to the roof deck.

[0008] The transition assembly for a roof deck and a parapet wall has abase component and a wall component. The base component, as in theperimeter assembly, has two legs. The first leg is attached to thecorrugated sheet of the roof deck, and the second leg extends generallyparallel to and overlaps a portion of the parapet wall. The second legagain has a connecting portion for securement to the wall component. Thewall component has a connector portion, and a hook portion. The hookportion extends over the top of the parapet wall, and the connectorportion overlays and is secured to the connecting surface of the basecomponent, thus anchoring the transition assembly to the roof deck andparapet wall.

[0009] The parapet wall transition assembly can further be fitted with acant component. The cant component is positioned at the intersection ofthe parapet wall and the roof deck. The cant component has a centralportion and a leg extending from each end of the central portion. Oneleg is secured to the roof deck and the second leg extends up theparapet wall and is secured to the wall component.

DESCRIPTION OF DRAWINGS

[0010] Drawings of a preferred embodiment of the invention are annexedhereto so that the invention may be better and more fully understood, inwhich:

[0011]FIG. 1 is a fragmentary perspective view of a roof perimetertransition assembly;

[0012]FIG. 2 is a cross-sectional view taken along line 2-2 of FIG. 1;

[0013]FIG. 3 is a cross-sectional view of a perimeter assembly installedon a roof deck having an incline;

[0014]FIG. 4 is a cross-sectional view of a wall transition assemblyinstalled on a roof deck with a parapet wall;

[0015]FIG. 5 is a perspective view of the base component of FIG. 4;

[0016]FIG. 6 is a cross-sectional view of the wall transition assemblyinstalled on a roof deck with a canted parapet;

[0017]FIG. 7 is a cross-sectional view of the transition assemblyinstalled at an expansion joint of a roof deck;

[0018]FIG. 8 is a cross-sectional view of the transition assemblyinstalled at a ridge on a sloped roof deck; and

[0019]FIG. 9 is a cross-sectional view of a transition assemblyinstalled at a valley formed in a sloped roof deck.

[0020] Numeral references are employed to designate like partsthroughout the various figures of the drawing.

DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

[0021] The roof perimeter and wall transition assemblies are designed tobe a part of the roof deck and are fastened to the roof deck. Theassembled components form structural units in conjunction with the roofdeck and are designed to respond to the forces roof decks typicallyencounter. The components acting in concert with the roof deck, resistuplift and diaphragm forces and protect the roof deck with an overlapdesign that accommodates relative movement between adjoining roof decksand other roof structures, such as parapet walls. Terms such as “left,”“right,” “clockwise,” “counter-clockwise,” “horizontal,” “vertical,”“up” and “down” when used in reference to the drawings, generally referto orientation of the parts in the illustrated embodiment and notnecessarily during use. The terms used herein are meant only to refer torelative positions and/or orientations, for convenience, and are not tobe understood to be in any manner otherwise limiting. Further,dimensions specified herein are intended to provide examples and shouldnot be considered limiting.

[0022] Referring to FIGS. 1 and 2, the numeral 10 generally designates aroof transition assembly for a roof deck 11 perimeter. Roof deck 11comprises a sheet of corrugated material 13 anchored to roof beams 14 byattachment means such as a threaded fastener or a plug weld 14 a, forexample as disclosed in U.S. Pat. No. 4,601,151, the disclosure of whichis incorporated herein by reference. A rigid substrate board 15, such asmineral board, is secured to the corrugated sheet 13. Interposed betweenthe rigid board 15 and the corrugated sheet 13 is at least one layer ofinsulation 18. The fasteners 16, which secure substrate board 15, extendthrough insulation layer 18 to corrugated sheet 13, but do not extendinto roof beams 14.

[0023] Transition assembly 10 comprises a base component 19 and an uppercomponent 20. Base component 19 is a strip of sheet metal, preferablygalvanized steel, with a C-shaped cross-section having generallyorthogonal legs 19 a and 19 b and a flange 19 c extending from thedistal end of leg 19 b. The gauge of sheet metal depends on itsapplication, but is typically 20 gauge steel for base components havingleg dimensions of 5 inches or less and 18 gauge steel for basecomponents having leg dimensions of 5 inches or greater. All of theassembly components are preferably galvanized steel and, therefore, donot buckle or warp from aging.

[0024] Leg 19 a of base component 19 extends between corrugated sheet 13and roof beam 14 and is secured to corrugated sheet 13 and roof beam 14by a fastener or a plug weld that extends through corrugated sheet 13and leg 19 a and into roof beam 14, as shown in FIG. 2. Therefore, leg19 a must extend into the roof deck far enough for proper securement tothe roof deck 11. Leg 19 b extends generally upwardly along edge 21 ofroof deck 11 and flange 19 c forms a lip that extends over the uppersurface 21 a of the roof deck 11 to provide an anchoring surface forupper component 20.

[0025] Upper component 20 similarly comprises a strip of sheet metal,preferably galvanized steel, with a comparable gauge to that of the basecomponent 19. Upper edge component 20 includes an anchoring portion 22for anchoring component 20 to the roof deck 11 and an invertedchannel-shaped connector portion 23 for overlapping with and securing tolip 19 c of base component 19. Anchor portion 22 extends into the roofdeck 11 between the rigid substrate board 15 and insulation 18 and issecured to the roof deck 11 by screw fasteners 16. It can be understoodthat rigid board 15 is secured to the corrugated sheet 13 by a pluralityof fasteners 16, typically in spaced apart rows that correspond to therows of ribs in the corrugated sheet. Therefore, lip 22 preferablyextends into the deck at least a minimum edge distance beyond the firstrow of fasteners in order to provide sufficient anchorage for normalloading conditions.

[0026] Channel-shaped connector portion 23 includes a web 23 a and apair of spaced apart flanges 23 b and 23 c, as best illustrated in FIG.2. Spaced apart flanges 23 b and 23 c straddle lip 19 c such that web 23a overlaps lip 19 c and is secured to lip 19 c by fasteners 24, such asbolts, screws or the like. It should be understood that a removableconnection is preferred, but the connector portion 23 can also be weldedto the base component 19, either through a plug weld between the web 23a and lip 19 c or a tack weld along the free edge of connector portion23 and leg 19 b.

[0027] The preferred embodiment illustrates only one method of placementof the transition assembly components. Base component 19 may be securedto the top or bottom of corrugated sheet 13, and upper component 20 maybe secured above or below rigid sheet 15. Also, the placement offasteners 24 is not critical, as long as the base and upper componentsare secured to one another. Further, the total fasteners used and exacttype and placement of fasteners is not critical. Fasteners may be addedor deleted as needed for the particular application.

[0028] In the first preferred embodiment, it can be seen that thecomponents 19 and 20 generally comprise orthogonal elements. It shouldbe understood, however, that the elements of the components, in otherwords, the legs, the flanges, and the webs, can be bent or formed toaccommodate roof decks that have angled edges or be customized to adesired angle to achieve a different architectural style. Such anarrangement is illustrated In FIG. 3.

[0029] In FIG. 3, roof deck 11 includes two layers of insulation 18 aand 18 b, with insulation layer 18 a inset from insulating layer 18 b.To accommodate the inset, the legs 19 a and 19 b of base component 19are formed or bent at an acute angle to one another. Lip 19 c generallyforms an obtuse angle with respect to second leg 19 b, but isapproximately parallel to first leg 19 a. The upper component 120 ismodified as well. Flange 23 b of channel shaped connector portion 23 isbent or formed at an obtuse angle with respect to web 23 a and is,therefore, not parallel to flange 23 c. Flange 23 b preferably is formedat an angle that is complementary to the angle between lip 19 c and leg19 b so that channel-shaped connector portion 23 fits over base member19 so that the two components will act together as a single structuralunit along with the roof deck.

[0030] The wall transition assembly 30, of FIGS. 4 and 5, is especiallysuitable for use at the junctures of roof decks and parapet walls. Asbest illustrated in FIGS. 4, and 5, wall transition assembly 30 includesa plurality of spaced apart base components 19′ and a wall component 32.Each base component 19′ comprises an L-shaped support member thatanchors the wall component 32 to the parapet wall 33 and to the roofdeck 11. Preferably, base component 19 has a width comparable to thelength of its first and second orthogonal legs 19 a′ and 19 b′. Leg 19a′ extends under wall 33 between insulation layer 18 and corrugatedsheet 13 of the roof deck 11 and is secured to corrugated sheet 13 byfasteners 16 and fasteners 34. Fastener 16 preferably extends throughrigid sheet 15, leg 19 a′ and corrugated sheet 13. It should beunderstood that the parapet wall increases the length of leg 19 a′ ofbase component 19′. Consequently, fastener 34 is preferred in order toreduce bending and deflection of base component 19. Fasteners may beadded on all transition assembly components as needed. Leg 19 b′ extendsup a portion of wall 33 between two layers of insulation 35 a and 35 bto provide an anchoring surface for wall component 32.

[0031] Wall component 32 comprises a strip of sheet metal, preferablygalvanized steel of comparable gauge to the base component 19′, with aninverted J-shaped cross-section having a hook portion 36 and a connectorportion 37 for extending to and overlapping with the second leg 19 b′ ofbase component 19′. Hook portion 36 includes a flange 36 a and a lip 36b which over-hang rigid sheet 31 of wall 33 so that when connectorportion 37 is secured to second leg 19 b′ of base component 19, flange36 a and lip 36 b will anchor the wall component 32 to the free edge ofwall 33 to form a tight connection with wall 33. Connector portion 37 issecured to leg 19 b′ of base member 19 by a fastener 38 that extendsthrough connector portion 37 and leg 19 b′. To ease installation andadjustment, base component 19′ may be provided with a slotted hole 39,as illustrated in FIG. 5. Fastener 16 a, which extends through rigidsubstrate 15 and insulation layer 18, preferably extends though leg 19a′ of base component 19′.

[0032] As best illustrated in FIG. 6, wall transition assembly 30 mayinclude a canted component 40. Canted component 40 may be added toimprove water run off near the parapet wall 33 or may be desired foraesthetic reasons. Canted component 40 comprises a strip of sheet metal,again preferably galvanized steel of similar gauge to the othertransition assembly components, with a substantially C-shapedcross-section. The C-shaped cross-section includes a central portion 41and a pair of legs 42 and 43 that extend from opposed edges of thecentral portion 41 at an angle of approximately 135 degrees with respectto the web 41. The angle between the legs 42 and 43 and the centralportion 41 is not critical and may be changed for design or aestheticpurposes. Legs 42 and 43 are substantially orthogonal to each other,with leg 42 extending between the rigid board 15 and the insulationlayer 18 of the roof deck 11, and with leg 43 extending between therigid board 31 and insulation layer 35 b of the parapet wall 33. Leg 42is secured to roof deck 11 by roof deck fasteners 16 that extend throughrigid substrate sheet 15 to the corrugated sheet 13. Similarly, leg 43is secured to wall 33 by fasteners 16 a that extend through rigidsubstrate board 31, insulation layer 35 b, leg 19 b of base component31, and connector 19 b′ of wall component 32.

[0033] A wedge shaped backing member 44 of insulation or other materialis preferably interposed between the central portion 41 of the cantedcomponent 40 and the juncture of the parapet wall 33 and the roof deck11 so that the canted component 40 will maintain its shape. The presenceand material of the backing member 44 is not critical.

[0034] Wall transition assembly 30 is especially suited for use atexpansion joints and can be combined with a second wall transitionassembly to ensure that both parapets of the expansion joint areprotected. The expansion joint structure illustrated in FIG. 7, isformed at the juncture of two adjoining roof decks 11 and 11′ that arespaced apart to accommodate relative movement between the two decks.Deck 11′ is similar in construction to roof deck 11 and canted parapetwalls 33 and 33′ are positioned at the edge of roof decks 11 and 11′,respectively. Insulation 45 may be interposed between the two walls 33and 33′ as needed. Wall transition assembly 30 and its mirror wallassembly 30′ are provided, which include mirrored canted components 40and 40′. Fasteners 16 a and 16 a′, and fasteners 38 and 38′ preferablyextend into insulation 45.

[0035] The description provided above has been limited to the roof deck,the roof deck supporting structure, and the transition assemblies, butit should be understood that the present invention may be used inconjunction with flashing and other roof components as needed ordesired. Furthermore, it should be appreciated that other and furtherarrangements of the disclosed structures may be used to achieve similarresults on different roofing configurations. For example, in FIGS. 8 and9, modified perimeter transition assemblies are used in conjunction atroof deck ridges and valleys. The assembly uses mirrored base components19 and 19′ and mirrored upper components 20 and 20′ wherein the twoassemblies are secured together by fasteners or welds. It should benoted that the transition assembly design eliminates the need forcontinuous supplemental support from some structural member from below.On a sloped roof, a supplemental support (not shown) is usually an angleiron or a bent steel plate. The edge termination system described hereinspans from joist to joist, eliminating the need for continuous supportbetween the joists. Note also that the roof deck termination structureof FIGS. 1, 2 and 3 are configured to carry shear loading to eliminatethe need for steel angles for supporting the perimeter of the roof deck.

[0036] While a composite roof deck constructed of corrugated sheets,insulation material and rigid sheets of gypsum board has been describedherein, it should be appreciated that the roof deck terminationstructure can be applied to roofs constructed of other materials andassembled in different manners. It is contemplated that the roof decktermination structure will be used in combination with materialsconventionally used for commercial and residential roof construction.

[0037] Although the preferred embodiments illustrate only one transitionassembly for clarity of explanation, typically a plurality of assemblieswould be spaced around the parapet wall or the perimeter of the roofdeck. The assemblies are placed around the roof deck perimeter to securecomponents of the roof deck to one another and to provide for stressreduction and roof protection. It is not critical that the same numberof base components be used as upper components or wall components. Oftena greater number of base components will be employed.

I claim:
 1. A transition assembly for a roof deck, the roof deckincluding a sheet of rigid material and a sheet of corrugated materialhaving top and bottom surfaces, the roof deck having an edge, said edgeintersecting an upper and a lower surface at corners, said transitionassembly comprising: a base component having first and second legs, andhaving a longitudinal extent generally parallel to the edges of the roofdeck, said first leg adapted to be secured to the sheet of corrugatedmaterial, and said second leg extending generally parallel to the edgeof the roof deck, said base component having a connecting surface; andan upper component having a connector portion, an anchor portion and alongitudinal extent generally parallel with the edges of the roof deck,and said anchor portion adapted to be secured to said roof deck, andsaid connector portion extending from said anchor portion and overlayingsaid connecting surface of said base component and secured to saidconnecting surface of said base component.
 2. A transition assemblyaccording to claim 1, wherein said connecting surface of said second legcomprises a lip which extends over the upper surface of the roof deck.3. A transition assembly according to claim 2, wherein said first legand said second leg of said base component are generally orthogonal andfurther wherein said lip and said first leg are generally parallel.
 4. Atransition assembly according to claim 1, wherein said connector portionof said upper component is generally channel-shaped having a web andspaced apart first and second flanges, said first flange extending fromsaid anchor portion to said web.
 5. A transition assembly according toclaim 2, wherein said connector portion of said upper component isgenerally channel-shaped having a web and spaced apart first and secondflanges, said first flange extending from said anchor portion to saidweb.
 6. A transition assembly according to claim 5, wherein said web ofsaid connector portion of said upper component is secured to saidconnecting surface of said base component.
 7. A transition assemblyaccording to claim 2, wherein said first leg of said base component isadapted to be secured to the bottom surface of said sheet of corrugatedmaterial.
 8. A transition assembly according to claim 2, wherein saidanchor portion of said upper component is adapted to be secured to saidroof deck between the sheet of rigid material and the sheet ofcorrugated material.
 9. A transition assembly according to claim 8,wherein said anchor portion of said upper component includes a nailingsurface.
 10. A transition assembly for a roof deck and a parapet wall,the roof deck including a sheet of rigid material and a sheet ofcorrugated material, the roof deck having an edge, said edgeintersecting an upper and lower surface at corners, the parapet wallincluding a sheet of rigid material and extending from the roof deckgenerally orthogonally to the roof deck, the wall having a free end,said wall and said roof deck joining at an intersection, said transitionassembly comprising: a base component having first and second legs andhaving a longitudinal extent generally parallel to the corners of theroof deck, said first leg adapted to be secured to the sheet ofcorrugated material, said second leg extending generally parallel to andoverlapping a portion of said wall, said second leg further having aconnecting surface; and a wall component having a connector portion, anda hook portion, and having a longitudinal extent generally parallel withthe free end of the wall, said hook portion extending over said free endof said wall, said connector portion overlaying and secured to saidconnecting surface of said base component.
 11. A transition assemblyaccording to claim 10, wherein said hook portion comprises a flange andlip, said flange extending from said connector portion, said lipextending from a distal end of said flange.
 12. A transition assemblyaccording to claim 11, wherein said flange of said hook component isgenerally orthogonal to said connector portion of said wall component.13. A transition assembly according to claim 10, wherein said second legof said base component includes a slotted hole for receiving a fastener.14. A transition assembly according to claim 13, wherein said wallcomponent is secured to said base component by a fastener extendingthrough said connector portion of said wall component and said slottedhole of said second leg of said base component.
 15. A transitionassembly according to claim 10, wherein said wall component and saidbase component are secured to said wall by a fastener which extendsthrough said connector portion of said wall component and said secondleg of said base component and into said wall. 16 A transition assemblyaccording to claim 10 for use at an expansion joint, which expansionjoint comprises first and second roof decks and first and second parapetwalls, said second roof deck and second parapet wall placed adjacent toand substantially mirroring the first roof deck and first parapet wallfurther comprising: a second transition assembly placed in a mirrorconfiguration with said transition assembly, such that said secondtransition assembly is attached to said second roof deck and said secondparapet wall.
 17. A transition assembly according to claim 10, furthercomprising a cant component, said cant component positioned at saidintersection of said wall and said roof deck, said cant component havinga longitudinal extent generally parallel with said corners of said roofdeck, and having a central portion and first and second legs extendingfrom opposed ends of said central portion, said second leg of said cantcomponent is secured to said wall component, and said first leg of saidcant component secured to said first leg of said base component.
 18. Atransition assembly according to claim 17, wherein said central portionforms an obtuse angle with said first and second legs of said cantcomponent.
 19. A transition assembly according to claim 18, wherein saidcant component further includes a backing member for interposing betweensaid central portion and said intersection between the wall and the roofdeck.
 20. A transition assembly according to claim 17, wherein saidfirst leg of said cant component is adapted to be secured between saidrigid material of said roof deck and said corrugated material of saidroof deck, and wherein said second leg of said cant component is adaptedto be secured between said rigid material of said wall and saidconnector portion of said wall component.
 21. A roof assemblycomprising: a roof deck having upper and lower surfaces and a perimeter,said perimeter intersecting said upper and lower surfaces, said roofdeck further having a corrugated sheet of material, said corrugatedsheet being adapted to be supported on roof beams, said roof deckfurther having a sheet of rigid material above said corrugated sheet,said rigid sheet having an upper surface and a lower surface, said lowersurface facing said corrugated sheet; a plurality of base componentsspaced apart and positioned at said perimeter of said roof deck, eachsaid base component having first and second legs and a longitudinalextent, said first legs secured to said corrugated sheet, and saidsecond legs extending generally parallel to said perimeter of said roofdeck and including a connecting surface; and a plurality of uppercomponents positioned at said perimeter of the roof deck, each saidupper component having a longitudinal extent, a connector portion, andan anchor portion, said anchor portion secured to said upper surface ofsaid roof deck, and said connector portion extending from said anchorportion and overlaying and secured to the connecting surface of at leastone said base component.
 22. A roof assembly as in claim 21 wherein:said connecting surface of said base components comprises a lip whichextends over said upper surface of said roof deck; and wherein saidconnector portions of said upper components are generally channel-shapedeach having a web and spaced apart first and second flanges, said firstflanges extending from said anchor portions to said web, wherein eachsaid web is secured to the connecting surface of at least one said basecomponent.